KR102626306B1 - Controlling apparatus, and method of producing article - Google Patents

Abstract

In a production system, the control unit controls a first machine configured to start operation after a waiting time and a second machine configured to start operating after a waiting time. The first sensor outputs a value that changes in response to the operation of the first machine. The second sensor outputs a value that changes in response to the operation of the second machine. The control unit compares a first period from the start of operation of the first machine to the occurrence of a change in the value of the first sensor with a predetermined first threshold, and changes the value of the second sensor from the start of operation of the second machine to the occurrence of a change in the value of the first sensor. A second period until the change occurs is compared with a second predetermined threshold value.

Description

Control device, and method of manufacturing an article {CONTROLLING APPARATUS, AND METHOD OF PRODUCING ARTICLE}

The present disclosure relates to a production system configured to monitor whether machines used in a production line are operating normally.

In a production line comprised of a plurality of machines controlled by a sequence control device, if a malfunction occurs due to machine deterioration, etc., the entire production line may stop until the broken machine is restored, resulting in a large production loss. To avoid such situations, early prediction of machine failure or early detection of deterioration can be performed so that predictive maintenance can be performed before failure occurs. To achieve this, it has been proposed to monitor the operating state of the machine (e.g., the timing at which the machine starts operating), automatically detect differences from normal operation, and notify the user of the detected differences. .

However, even in normal operation, there is some gap in operation time. This gap may vary depending on the machine.

For example, Japanese Patent No. 5021547 discloses a technique for measuring the operating timing of each of a plurality of devices of an automatic machine during normal operation and creating reference timing data. The actual operating timing is detected and compared with reference timing data.

In production lines, there is a tendency to control multiple machines using one control device to lower costs. However, in a production line, parts cannot be supplied from the current process to the next process until the current process is finished. For this reason, if a problem occurs in a specific process, the machine in the next process cannot operate. In many control methods, when parts are supplied to the machine, the machine starts operating. Therefore, all machines do not necessarily start operation at the same timing.

As in the technology disclosed in Japanese Patent No. 5021547, in order to monitor whether or not each of a plurality of machines with different operation start timings is operating normally based on the ON/OFF time of each machine, a measurement standard is set for each signal. It is necessary to provide this in advance.

However, in the technology disclosed in Japanese Patent No. 5021547, as the number of machines and signals controlled by one control device increases, the amount of work required to provide measurement standards for each signal increases, so manual work is required. A significant increase in workload occurs.

In one aspect, the present disclosure provides a control, in a production line comprising a plurality of sensors and a plurality of devices, configured to acquire information about the device, wherein the sensor is configured to output a sensor signal in accordance with operation of the device. An apparatus, comprising: a control unit configured to operate a first apparatus and a second apparatus among the plurality of apparatuses based on a control signal, the sensor signal, the control signal, and operation of the first apparatus and the second apparatus; and a monitoring unit configured to acquire operation information, wherein the control unit causes the first device to operate in a first cycle, based on the control signal, and causes the first device to operate in a second cycle following the first cycle. causing the device and the second device to be activated, the monitor comprising: a first sensor signal and a first control signal associated with the first device, the sensor signal and the first control signal having changed while the first device is operating in a first cycle; Identifying a control signal, the monitoring unit, a second sensor signal and a second control signal associated with the second device, the first of the sensor signal and the control signal changed while the second device is operating in a second cycle. 1 A control device that identifies the sensor signal and the control signal other than the sensor signal and the first control signal is provided.

In one aspect, the present disclosure provides a method of information processing.

Hereinafter, various embodiments, features and aspects of the present invention will be described in detail with reference to the accompanying drawings.

1 is a block diagram illustrating a system configuration according to one or more aspects of the present disclosure.
2 is a diagram illustrating the configuration of a production line according to one or more aspects of the present disclosure.
3A-3C are operational timing charts according to one or more aspects of the present disclosure.
4 is a diagram illustrating a list of signal uses according to one or more aspects of the present disclosure.
5 is an operational timing chart for signals extracted from the charts shown in FIGS. 3A-3C, i.e., only signals with signal numbers used by process number A, in multiple cycles, in accordance with one or more aspects of the present disclosure. It is shown across.
6A and 6B are diagrams showing measurement results according to one or more aspects of the present disclosure.
7A and 7B are diagrams showing decision conditions according to one or more aspects of the present disclosure.
8 is a diagram illustrating an example of a screen of a display unit according to one or more aspects of the present disclosure.

Referring to FIG. 1, one embodiment of the present disclosure will be described.

In the production line 100, products are manufactured through manufacturing processes 101 to 103 performed by a plurality of machines that can operate independently. Each machine performing the corresponding process among processes 101 to 103 is composed of a plurality of sensors, pneumatic devices, robots, etc. Each process 101 to 103 is controlled by controlling each corresponding machine using a control unit. Specifically, for example, each process is controlled by sequence control using one programmable logic controller (PLC) 110. The programmable logic controller (PLC) 110 may be a control device or controller. In the present disclosure, a control unit, PLC, control device, or controller configured to control machines used in each process 101 to 103 is referred to as a control unit.

The monitoring device 120 is configured, for example, by installing a program on a general-purpose computer. The monitoring device 120 may be equipped with a processor (CPU), memory, and a large capacity non-volatile storage device such as a magnetic disk device. The monitoring device 120 may further include a display unit 160 such as a display and an input device 150 such as a mouse and/or keyboard. In Figure 1, the monitoring device 120 is installed separately from the controller 110, but it is not limited to this. The monitoring device 120 may be a part of a computer that implements the controller 110, or the monitoring device 120 and the controller 110 may be implemented in the same control unit. In the present disclosure, since the monitoring device 120 is a part of a computer that implements the controller 110, the monitoring device 120 in FIG. 1 may be referred to as a monitoring unit or a control unit. In the present disclosure, the entire production line 100, control device 110, and monitoring device 120 are referred to as a production system.

In FIG. 1, the recording processing unit 111 of the controller 110 stores the current value of a signal indicating the operating state and/or the current value of a signal related to each machine in each process from a storage unit (sometimes referred to as a memory). is read in accordance with the processing clock of the PLC 110, and the read value is transmitted to the monitoring device. The monitoring device receives the transmitted operation status and/or signals related to each machine of each process and stores them in the storage unit as the operation status 131 or signal 132. When the monitoring device is implemented as a monitoring unit installed in the same computer in which the controller is implemented as described above, there is no need to transmit or receive values, but signals indicating the operating status of each process are stored in the memory provided in the controller. and/or the signal may be used as is. The operating state of each machine in each process is the operating state 131 and is stored at predetermined time intervals or timings. For example, when the machine is operating in the relevant processes (101 to 103), 1 is used as the number. On the other hand, if the machine is in a standby state in the process, 0 is used as a number. Regarding the signal 132, a control signal used by the controller 110 to control each machine used in each process 101 to 103 is stored at predetermined time intervals or timings. The control signal is used to notify the controller 110 that a sensor installed in each machine operating in each process 101 to 103 has detected a work, or is used to notify the controller 110 of each machine used in each process 101 to 103. It is used to instruct the user to initiate an operation. For example, if the sensor detects a work, a value of 1 is stored in the controller's memory (sometimes called memory), but if a work is not detected, a value of 0 is stored. These values are read by the recording processing unit 111 of the controller 110 and transmitted to the monitoring device. The monitoring device stores each received signal as a signal 132 in the memory.

Next, the operation status 131 and signal 132 stored in the memory of the monitoring unit for each machine in each process will be described in detail with reference to Figs. 2 and 3A to 3C.

Figure 2 is a simplified representation of the production line. Each machine in each process has an input unit 203, an adhesive application unit 207, and an discharge unit 209, and the workpieces manufactured in each manufacturing process are conveyed by a conveyor 204. In the embodiment shown in Fig. 2, these units are controlled by one controller. The input unit 203, adhesive application unit 207, and discharge unit 209 shown in FIG. 2 are respectively used for process A (first process) 101 and process B (second process) 102 shown in FIG. 1. and process C (third process) (103).

FIGS. 3A to 3C are operation timing charts showing the operating status of each unit of the production line shown in FIG. 1. On the left side of these drawings, process numbers 1 to 3, names of machines (units) used in these processes, and their states (operating state or standby state) are shown. Below it, signals X1 to To their right, timing charts are shown indicating the status of machines and signals. The horizontal axis of the timing chart represents the passage of time.

Next, the operation of each machine in each process controlled by sequence control using one controller 110 will be explained with reference to the operation timing charts shown in FIGS. 3A and 3B. First, when the input pallet 202 is set, the input unit 203, which was in a standby state, starts operation. That is, the input unit 203 is in an operating state. That is, the input unit 203, which was in a standby state, starts operation. In other words, process A is in operation. In FIG. 3A, the state of the input unit of process A transitions from the standby state (0) to the operating state (1) (301 in FIG. 3A). In response to this transition, the value 1 of the signal indicating that process A is in operation and its start time are stored in the controller's memory. In this embodiment, the timing at which the state of process A transitions from the standby state to the operating state is the timing when the input pallet is set, but it is not limited to this. For example, in contrast, the transition of the state of process A from the standby state to the operating state may occur when a certain period of time has elapsed from the transition of the state of the input unit from the operating state (1) to the standby state (0). do.

When process A (input unit 203) is in the operating state, a command signal is generated to close chuck C1, which is placed in the input unit 203 and serves to grip the work (that is, signal Y1 in FIG. 3b changes from 0 to changes to 1). At the same time, the signal value 1 of the command signal Y1 and the generation time of the command signal Y1 are stored in the memory of the controller. When the command signal Y1 to close the chuck C1 is generated, the chuck C1 closes and grips the work 201 on the pallet. Sensor S1 configured to detect the closed state of the chuck C1 detects the closed state of the chuck C1. That is, the signal symbol

When the chuck C1 is detected to be closed, a command signal is generated to turn the robot R1, which functions as the insertion unit 203, around the X axis. Specifically, a pulse signal that changes from 0 to 1, which functions as a command signal with the symbol Y6, the value of this signal, 1, and the generation time of this command signal are stored in the memory of the controller. In response to the generation of the command signal, the robot R1 turns and the work 201 moves on the conveyor 204. Sensor S6 (not shown) detects whether the turning position of robot R1 is normal. When sensor S6 detects that the turning position of robot R1 is normal (when sensor S6 outputs a signal with signal symbol In response to detecting that the turning position of the robot R1 is normal, a command signal to open the chuck C1 is generated (the command signal with symbol Y2, which has the form of a pulse signal, changes from 0 to 1). Accordingly, the value 1 of the command signal and the generation time of the command signal are stored in the memory of the controller. In response to the generation of a command signal, the chuck C1 is opened and the work 201 is placed on the conveyor 204. When the sensor S2 installed to detect the open state of the chuck C1 detects that the chuck C1 is open, the value of the signal with the signal symbol It is stored in the memory of this controller. In response to detecting that the chuck C1 is open, the sensor 205 of the work detection unit W1 detects whether the work 201 exists on the conveyor 204. When the sensor 205 detects that the work 201 exists on the conveyor 204, the value of the signal with the signal symbol remembered in memory. In response to detecting the presence of the workpiece 201, a command signal is generated to turn the robot R1 around the X axis. That is, the value of the command signal having the signal symbol Y5 in the form of a pulse signal is changed from 0 to 1, and the value of this signal, 1, and the generation time of the command signal are stored in the memory of the controller. In response to the generated command signal, robot R1 turns until it reaches the return position. Sensor S5 (not shown) detects whether the return position of robot R1 is normal. When S5 detects that the return position of robot R1 is normal (when the value of the signal with the signal symbol X5 output by sensor S5 becomes 1). The signal value of 1 and the detection time are stored in the controller's memory. In response to detecting that the return position of the robot R1 is normal, the input unit 203 enters a standby state, and the value of the signal indicating the state of the input unit 203 becomes 0. This value and the detection time are stored in the controller's memory. That is, in FIG. 3A, the state of the input unit in process A transitions from the operating state (1) to the standby state (0) (301 in FIG. 3A).

When the sensor 205 of the work detection unit W1 detects the work 201 placed on the conveyor, the conveyor 204 is driven to transport the work 201. When the sensor 206 of the work detection unit W2 detects the work 201, the value of the signal with the signal symbol X9 output from the sensor 206 becomes 1, and the conveyor stops. The signal value of 1 and the detection time are stored in the controller's memory.

In addition, in response to the detection of the work 201 by the sensor 206 of the work detection unit W2, the input unit 203, which was in a standby state, resumes operation, and the value of the signal indicating the state of the input unit 203 changes from 0 to 1. is changed to That is, in FIG. 3A, the state of process A (input unit) transitions from the standby state (0) to the operating state (1) (302 in FIG. 3A). The value 1 of this signal and its detection time (operation start time) are stored in the memory of the controller, and the above-described operation is repeated.

Additionally, the adhesive application unit 207, which was in a standby state, starts operation. In other words, process B is in operation. That is, in FIG. 3A, the state of the adhesive application unit of process number B transitions from the standby state (0) to the operating state (1) (311 in FIG. 3A). The value of the signal indicating the state of process B (adhesive application unit 207) is 1, indicating that process B is in operation, and the value of this signal 1 and its detection time (operation start time) are set to 1 by the controller. is remembered in memory. Additionally, in response to detecting the work 201, a command signal is generated to advance the dispenser of the adhesive application unit 207 along the X-axis. That is, a signal with a value of 1 is output as a command signal with the signal symbol Y7. Furthermore, a command signal for discharging adhesive is generated from the dispenser, that is, a signal with a value of 1 is output as a command signal with the signal symbol Y9. The value 1 of the command signal and the generation time of the command signal are stored in the memory of the controller. Accordingly, the dispenser of the adhesive application unit advances the X-axis while discharging the adhesive to apply the adhesive to the work 201. Sensor S7 (not shown) installed to detect the forward position of the X-axis detects the dispenser, and a signal with a value of 1 as a signal with the signal symbol The value 1 of this signal and the detection time are stored in the controller's memory. When the sensor detects the dispenser, the value of the command signal Y9, which controls discharge from the dispenser, transitions from 1, which indicates that discharge is performed, to 0, which indicates that discharge is stopped. When the value of the command signal changes from 1 to 0, the signal value 0 and the time at which it transitioned to 0 are stored in the memory of the controller. Furthermore, a command signal is generated to retract the X axis. That is, the value of 1 is output as a command signal with the signal symbol Y8, and the value of this signal, 1, and the time when the command signal was generated are stored in the memory of the controller. In response to this, the dispenser of the adhesive application unit retracts along the X-axis. When sensor S8 (not shown) installed to detect the retracted position of the It is stored in the controller's memory. In response to this, the adhesive application unit 207 enters a standby state, and the value of the signal indicating the state of the adhesive application unit 207 (process B) becomes 0, indicating that the adhesive application unit 207 is in a standby state. . This value and its detection time are stored in the controller's memory. In FIG. 3A, the state of process B (adhesive application unit) transitions from the operating state (1) to the standby state (0) (311 in FIG. 3A).

When both process B and process A are in a standby state, the conveyor 204 is driven to transport the work 201. When the sensor 208 of the work detection unit W3 detects a workpiece, that is, when the value of the signal with the signal symbol At the same time, the sensor 206 of the work detection unit W2 also detects the work. When the sensor 206 detects a workpiece, the value of the signal with the signal symbol In response, the conveyor stops.

When the sensor 208 of the work detection unit W3 detects the work 201, process A, which was in a standby state, resumes operation. In FIG. 3A, the state of the input unit of process A transitions from the standby state (0) to the operating state (1) (303 in FIG. 3A). A value of 1 indicating that process A (input unit 203) is in an operating state and its time (operation start time) are stored in the memory of the controller. The above-described operation is repeated. In this way, Process A is operated repeatedly with a waiting time between repetitions of Process A. That is, operation resumes after each waiting period.

In response to this, process B, which was in a standby state, starts operation. That is, the adhesive application unit 207 is in an operating state. In FIG. 3A, the state of the adhesive application unit of process number B transitions from the standby state (0) to the operating state (1) (312 in FIG. 3A). At the same time, the value 1 of this signal related to process B (adhesive application unit 207) and its detection time (operation start time) are stored in the memory of the controller, and the above-described operation is repeated. In this way, process B is operated repeatedly with a waiting time between repetitions. That is, operation resumes after each waiting period.

When the sensor 208 of the work detection unit W3 detects a work, process C (discharge unit 209), which was in a standby state, starts operation. The value of the signal indicating that process C (discharge unit 209) is in operation (1 in this embodiment) and its time (operation start time) are stored in the memory of the controller.

In response to this, the discharge unit 209, which was in a standby state, starts operation. In other words, process C is in operation. In FIG. 3A, the state of the discharge unit 209 of process number C transitions from the standby state (0) to the operating state (1) (321 in FIG. 3A), the value of the signal indicating the state of process C is 1, and it The detection time is stored in the memory of the controller. Furthermore, a command signal is generated to close chuck C2 of the discharge unit 209. That is, a signal with a value of 1 is generated as a command signal with the signal symbol Y10, and the signal value of 1 and its detection time are stored in the memory of the controller. In response to this, the chuck C2 closes and grips the work 201 on the conveyor. When sensor S10, which is installed to detect the closed state of chuck C2, detects that chuck C2 is closed, the value of the signal displayed by the signal symbol X10 output from sensor S10 becomes 1, and the signal value is 1. And, the detection time is stored in the memory of the controller. A command signal is generated to turn the I axis of the robot R2, which functions as the discharge unit 209. That is, a signal with a value of 1 is generated as a command signal indicated by the signal symbol Y13, and the value of this signal, 1, and the time at which this command signal was generated are stored in the memory of the controller. In response to this, the I axis of robot R2 turns and moves the work 201 on the discharge pallet 210. When sensor S15 (not shown) installed to detect whether the turning position of robot R2 is normal or not detects that the turning position is normal, the value of the sensor signal indicated by the signal symbol X15 becomes 1, and the value of 1 of this signal and The detection time is stored in the controller's memory. In response to this, a command signal is generated to open chuck R2. That is, a signal with a value of 1 is generated as a command signal indicated by the signal symbol Y11, and the value of this signal, 1, and the time at which this command signal was generated are stored in the memory of the controller. In response, the chuck C2 opens and the work 201 is placed on the discharge pallet 210. When the open state of the chuck C2 is detected by the sensor S11 installed to detect the open state of the chuck C2, the sensor S11 outputs a signal with a value of 1 as a sensor signal indicated by the signal symbol 1 and the detection time are stored in the memory of the controller. In response to this, a command signal is generated to cause the I axis of robot R2 to turn. That is, a signal with a value of 1 is generated as a command signal indicated by the signal symbol Y12, and the signal value of 1 and the time at which the command signal was generated are stored in the memory of the controller. In response, the I axis of robot R2 pivots until it reaches the return position. When sensor S14 (not shown) installed to detect whether the return position of robot R2 is normal or not detects that the return position is normal, sensor S14 outputs a signal with a value of 1 as a sensor signal indicated by the signal symbol X14, The signal value of 1 and the detection time are stored in the controller's memory. In response, process C (discharge unit 209) goes into standby. That is, in FIG. 3A, the state of the discharge unit of process number C transitions from the operating state (1) to the standby state (0) (321 in FIG. 3A), indicating the state related to process C (discharge unit 209). The value of 0 and its detection time are stored in the controller's memory.

In this embodiment, the period during which each process (process A, process B, process C) applies or conveys parts (works) of the product to be manufactured is expressed as one cycle.

When the production line starts operating with no work on the conveyor, only process A (input unit 203) operates in the first cycle. In the second cycle, process A (injection unit 203) and process B (adhesive application unit 207) operate. In the third cycle, all units and processes including process A (input unit 203), process B (adhesive application unit 207), and process C (discharge unit 209) are operated.

In the third cycle and subsequent cycles, all units operate until there are no works inside the input pallet 202. If there are no works in the input pallet 202 in a specific cycle, the input unit 203 does not operate (the waiting time becomes longer than a predetermined value). In the next cycle, the workpiece is not supplied to the adhesive application unit 207, so the adhesive application unit 207 does not operate. In the next cycle, no work is supplied to the discharge unit 209, and the discharge unit 209 does not operate (the waiting time becomes longer than a predetermined value).

When N pieces of work initially exist in the input pallet, N number of cycle operations are performed until no work exists in the input pallet and all units become inoperable (until the waiting time becomes greater than a predetermined value). . That is, in each process, each machine runs repeatedly with waiting times between repetitions. That is, after each waiting period, each machine in each process resumes operation.

The recording processing unit 111 of the controller 110 processes the value of the signal indicating the operating state of each machine in each process and the value of the signal related to each machine from the memory of the controller 110. It is read in accordance with the clock, and the read signal is transmitted to the monitoring device. The monitoring device receives the transmitted operation status signals of each process and signals related to each machine, and stores them as operation status 131 and signal 132 in the storage unit. In the production line shown in FIG. 2, an input pallet is set on the conveyor 204 without any work. The operation status 131 and signal 132 related to each machine in each process are recorded until there are no works in the input unit and all units are not in operation (until the waiting time is greater than a predetermined value). do.

Next, using the operating states 131 and signals 132 associated with each of these recorded processes, the monitoring device 120 controls the machine as described with reference to FIGS. 1, 2, and 3-3C. monitor.

The monitoring device 120 has a program that creates conditions for monitoring the devices of each machine in each process, and a program that monitors the devices of each machine in each process. First, a program for creating conditions for monitoring the equipment of each machine in each process will be explained. The program for creating conditions for monitoring the equipment of each machine in each process has an analysis processing unit 141 and a judgment condition creation unit 142.

The role of the analysis processing unit 141 is to automatically determine which signals are used by each machine device in each process in the production line. Specifically, from the operation status 131 of each device in each process stored in the storage unit of the monitoring unit and the signals 132 related to each device, the analysis processing unit 141 is in an operation state in the production line 100. The signals used in each machine are automatically determined in each process, and the analysis processing unit 141 stores the results as a used signal list 133.

In a production line, work is done on the work in order, so the number of machines starting operation increases step by step and progressively until the work reaches all the machines that previously did not have the work. In other words, when machines start operating sequentially, the signal value corresponding to the machine sequentially changes from a value representing a standby state to a value representing an operating state, thereby determining the signal used by each machine in each process. is detected.

First, for example, when an operator inputs an instruction to the monitoring device 120 using an input unit (not shown), the analysis processing unit 141 starts operation. Initially, the analysis processing unit 141 prompts the operator to enter an analysis period. In this state, for example, the period between when a work is introduced into a production line and when a finished product is discharged, when there is still no work and all machines in the process are on standby (as indicated by signals associated with each process). The operator enters a value that specifies the period including. The analysis processing unit 141 reads the operation status 131 and signals 132 related to each machine in each process for a designated period, extracts necessary data, and starts analysis.

When the operating state 131 of the machine of each process has a constant value over a specific period, the analysis processing unit 141 determines that this process is in a specific operating state during this specific period. 3A to 3C are graphs showing recorded values of operating states 131 and signals 132 associated with each machine in each process. Specifically, the process number and signal number are shown along the vertical axis, the time is shown along the horizontal axis, and the signal of each process number and the signal of each signal number are displayed in time series.

In FIGS. 3A to 3C , 301, 302, and 303 represent periods during which the input unit of process number A is in operation. 301 represents the first operation period, 302 represents the second operation period, and 303 represents the third operation period. Similarly, 311 and 312 represent the period during which the adhesive application unit of process number B is in operation. 311 represents the first operation period, and 312 represents the second operation period. 321 indicates the period during which the discharge unit of process number C is in operation. 321 indicates the first operation period. At this time, the operation period is the period from the time when the transition from the standby state (0) to the operation state (1) occurs to the time when the transition occurs from the operation state (1) to the standby state (0).

The analysis processing unit 141 extracts a signal whose value indicating the operation state changes between ON (1) and OFF (0) within the same operation period for the same process number, and converts the signal symbol of the extracted signal to this process. Used as a signal symbol in use. Accordingly, the analysis processing unit 141 creates a use signal list 133 as shown in FIG. 4.

When all processes (process numbers A to C) are operating, as in the case of the first operation period 321 of process number C (discharge unit) shown in FIG. 3A, from the signals related to each process, the information used in the specific process Detecting machine signals may not be easy. However, taking advantage of the fact that there is a gradual, stepwise increase in the number of machines used in a process when it starts operating, it is possible to accurately detect the signal signature of signals associated with a particular process.

Specifically, for example, during the first operation period of process number A (input unit 203) indicated by 301 in FIG. 3A, only process number A (input unit) is in operation. If a change in value of a specific signal is detected between ON (1), indicating an operating state, and OFF (0), indicating a standby state, within this period, it can be determined that this specific signal is a signal associated with the putting unit. In the first operation period 301 of process number A (input unit) in FIG. 3A, the change in signal value indicating the operation state between ON (1) and OFF (0) is in area 304 (FIG. 3A) and area 305 (FIG. 3B). ) occurs in That is, it can be determined that signals having signal numbers X1, X2, X3, X5, In the second operation period of process number A (input unit) indicated by 302, not only process A (input unit 203) but also process B (adhesive application unit 207) is in operation. Based on the difference from the first operation period 301 in which only process number A (injection unit 203) is operating, the signal used in process number B (adhesive application unit 207) can be detected as follows. . In other words, the signal to be detected does not have a change in signal value between ON(1) and OFF(0) in the operation period 301, but in the operation period 311, the signal indicates an operation state between ON(1) and OFF(0). Has a change in value. It can be determined that these detected signals are signals used in process number B (adhesive application unit 207). That is, these signals are detected within areas 313 and 314. Accordingly, signals having signal numbers X7, X8, X9, Y7, Y8, and Y9 are signals associated with the adhesive application unit 207.

Similarly, based on the difference in signals between the first operation period 321 of process number C (discharge unit) and the second operation period 302 of process number A (input unit), process number C (discharge unit 209) Signals used in can be detected. Specifically, in the operation period 302, there is no change in the value representing the operation state between ON (1) and OFF (0), but in the operation period 321, by detecting a signal with a change between ON (1) and OFF (0) , the signal used in process number C (discharge unit 305) can be detected. That is, since signals with values indicating that the operating state changes between ON (1) and OFF (0) are found within areas 322 and 323, signal numbers X10, , Y12, and Y13 are detected.

The relationship between the signals and the operation status of the process determined in this way is preserved as a use signal list 133. Figure 4 shows an example of the use signal list 133 according to this embodiment.

As mentioned above, on a production line the number of operating machines increases gradually and step by step, and the fact that the signals used for a particular machine have a change in signal value between ON or OFF only when this particular machine is in operation. Based on this, the signals used by the machine in the operating state are detected.

Alternatively, even if specified by the operator and input into the analysis processing unit 141, the period may be the period from the state in which all processes in the production line are operating (state in which all processes have works) to the state in which all works have been discharged. . In this case, during the period from the state in which all processes in the production line are running (all processes have works), through the state in which the input of works to the process is continuously stopped, to the state in which all works are discharged, Step by step and progressively the number of operating machines is reduced. Even using the data acquired during this period, it is possible to detect signals associated with each machine used in the corresponding process, as in the case of acquiring data as described above with reference to FIGS. 3A to 3C. Therefore, as mentioned above, the operator must specify the period from the state in which all processes in the production line are running (all processes have works) to the state in which all works have been discharged after stopping work input. For this purpose, a value may be entered into the analysis processing unit 141.

In a production line, multiple machines may operate at the same timing. For example, this situation may occur if the production line includes not only one but also two adhesive application units 207 and the adhesive is applied to one workpiece by two adhesive application units 207 at the same time. . In this case, in the above-mentioned method, it is possible to detect whether the signal is used by the first adhesive application unit or the second adhesive application unit. However, this method cannot determine whether this signal is used by the first adhesive application unit or the second adhesive application unit.

When a plurality of machines operate at the same timing, signals are accurately detected, for example, by a method described below.

Between sensors (S1, S2, 205, S5, S6, S7, S8, 206, S10, S11, 208, S14, S15) due to various factors such as reaction speed, control signal transmission time, and machine sliding resistance. There may be slight differences in ON/OFF timing. Even the same machine does not necessarily operate at the same timing. When a machine starts using a signal, the ON-OFF transition of the machine's running state occurs in response to the sensor's ON signal. Therefore, generally, the difference between the end timing of the running state and the ON timing of the signal is rather small. Accordingly, candidate machines can be narrowed down. The period indicated by 331 in FIG. 3, that is, the period from the time the signal is on to the time the operating state ends, is measured for a plurality of cycles, and the machine showing the smallest deviation from this measured period uses this signal. I think it's a machine that exists. By doing this, even when the operation timing is similar among a plurality of machines, the signals used by each machine can be accurately detected based on the operating status of each machine.

Next, a method for creating monitoring conditions for a machine will be explained with reference to FIGS. 1, 4, 5, and 6A and 6B.

When an operator gives an instruction to create a decision condition to the decision condition creation unit 142 shown in FIG. 1, the creation of the monitoring condition starts. The decision condition creation unit 142 creates decision conditions as shown in FIGS. 7A and 7B with reference to the signal use list shown in FIG. 4. Below, the process of creating judgment conditions will be described in more detail.

Multiple judgment conditions may be defined in each row of the signal use list. An example of a method for determining whether a signal is normal or abnormal is described below. In this method, determination conditions are defined using the ON timing and OFF timing of the signal according to this embodiment.

The ON timing and OFF timing of the signal represent the time from the start of process operation (1) to the transition of the signal to ON (1) or OFF (0). Figure 5 is an operation timing chart over multiple cycles, relating only to signals extracted from the charts shown in Figures 3A to 3C, i.e., signals with signal numbers used by process number A (input unit 203). . In Figure 5, t1, t2, and tn each represent ON timing, and T1, T2, and Tn each represent OFF timing. Specifically, in Fig. 5, t1 represents the ON timing of the 1st cycle of signal X1, and tn represents the ON timing of the nth cycle of signal X1. In Fig. 5, T1 represents the OFF timing of the 1st cycle of signal X1, and Tn represents the OFF timing of the nth cycle of signal X1.

There may be slight differences in ON or OFF timing between sensors due to various factors such as reaction speed, control signal transmission time, and machine sliding resistance. Accordingly, values are measured over multiple cycles and the measured values are processed statistically to determine a decision threshold that defines an acceptable gap from steady state.

When the decision condition creation unit 142 shown in FIG. 1 starts creating monitoring conditions, the decision condition creation unit 142 prompts the operator to input an analysis period. In response, the operator specifies a period comprising a plurality of cycles, such as that shown in Figure 5, during which the processes were performed normally. The decision condition creation unit 142 reads the operation state 131 and signal 132 for a designated period.

As an example, the first row of the use signal list shown in FIG. 4 will be described. The first line describes the signal with the signal symbol X1. As can be seen from the list of used signals, a signal with the signal symbol X1 is used in process A (input unit). Therefore, the ON timings t1, t2,... from the operation status and signals read as shown in FIG. 5. , tn and OFF timing T1, T2, … , Tn is determined. Specifically, the time from the start of operation to each transition to ON and the time from the start of operation to each transition to OFF are determined. Figures 6a and 6b show the decision results. In FIGS. 6A and 6B, the first row shows the ON timing and OFF timing of signal X1 shown in FIG. 4 over a plurality of cycles.

The average value and deviation obtained for all cycles are calculated separately for ON timing and OFF timing, and separately for each item. Next, the upper and lower limits of the threshold are calculated, for example, as the average value ±6 × deviation. If the timing is within the above-mentioned range, the signal is recorded as a normal signal, but otherwise, the signal is recorded as an abnormal signal. After calculating threshold values for all items in the used signal list, the resulting decision conditions and decision threshold values are described in a list, for example, as shown in FIGS. 7A and 7B. The decision conditions and decision threshold values listed in FIGS. 7A and 7B may be used as the decision condition 134 in FIG. 1 .

In this embodiment, the operation status of each machine in each process is such that when work is performed on a workpiece by the machine during a certain period, the signal has a value of 1, while the machine is in a standby state and waits for the arrival of the workpiece. In this case, the signal value is expressed as one of two values so that it has a value of 0. However, the signal may take on different values depending on the operation pattern of each machine in the corresponding process. For example, when producing products of multiple models on one production line, the operation status for each model is defined and displayed as a value. For example, when work is performed on model A, the operation status has a value of 1. When work is performed on model B, the operating state is displayed with a value of 2, and the waiting state in which the machine waits for the arrival of the work is displayed with a value of 0. By doing this, even when the operation pattern of the machine changes depending on the model, that is, the ON/OFF timing of the signal changes depending on the model, the monitoring state can be easily set for each operating pattern of the machine.

Next, the program that monitors the production line, the determination unit 143, and the display processing unit 144 will be explained.

The determination unit 143 automatically starts operation when the determination condition 134 is created. When a new operating state 131 or signal 132 is recorded in the monitoring device 120, the determination unit 143 determines the signal based on the determination condition 134. When the threshold value is exceeded, the signal is determined as an abnormal signal, and the occurrence time of the abnormality and the signal symbol of the signal with the abnormality are recorded in the storage unit as a history (anomaly occurrence history) 135.

The display processing unit 144 has the role of notifying the operator of the occurrence of an abnormality. When the abnormality occurrence history 135 is updated, the display processing unit 144 displays the abnormality occurrence history 135, process operation status 131, signals 132, and judgment conditions 134 in a visually easy-to-understand chart. Editing is performed, and the resulting chart is displayed on the display unit 160.

Next, a method for monitoring the production line will be explained with reference to FIGS. 1 and 8.

When the decision condition 134 shown in FIG. 1 is recorded in the monitoring device 120, the monitoring device 120 starts monitoring the signal 132. The determination unit 143 periodically operates and determines the signal 132 based on the determination condition 134. When the signal 132 exceeds the threshold, the time of occurrence of exceeding the threshold, the process number, and the signal symbol are recorded as the abnormality occurrence history 135.

The display processing unit 144 notifies the operator of the occurrence of an abnormality by displaying the updated abnormality occurrence history 135 on the screen of the display unit 160. Figure 8 shows an example of a screen displayed on the display unit 160 of the display processing unit 144. In Figure 8, 801 indicates the period of the currently displayed abnormality occurrence history. In this embodiment, the abnormality occurrence history within a predetermined period (for example, one week) from the screen update date and time is displayed. In FIG. 8, 802 indicates an abnormality occurrence history 135 displayed in table format during the display period indicated by 801.

The operator can determine the occurrence of an abnormality and the abnormal situation from the abnormality occurrence history 802. Next, the operator selects a specific abnormality history 802, and more detailed information is displayed. In response to the operator's selection, the operating status and signals when an abnormality occurs are displayed in chart format in the lower area of the screen. In Figure 8, 803 represents a selection member (e.g., a tab) displayed on a screen that allows selection of a machine in each process displayed in chart format. In FIG. 8, 804 displays the operation status of each process in the form of a bar chart, and the part without bars indicates a standby (0) state. In FIG. 8, 805 displays a signal in the ON (1) state in the form of a bar chart, and the parts without bars each display the OFF (0) state. In FIG. 8, 806 and 807 are visual indications of the threshold value (decision threshold) of the decision condition 134 shown in FIG. 1. More specifically, the broken line indicated by 806 in FIG. 8 indicates the normal range of the ON timing of the signal, and the broken line indicated by 807 in FIG. 8 indicates the normal range of the OFF timing of the signal. In Figure 8, 808 indicates the range in which the signal is considered abnormal as the signal ON timing is outside the normal range indicated by the dashed line. To make the abnormality easier to understand, the abnormal range 808 may be displayed in a different color from the normal range. In response to selecting a machine in a process by selecting a selection member displayed on the screen, a signal number and signal name associated with the machine in the process and/or a corresponding bar chart are displayed. In Figure 8, for example purposes, a tab is used as a selection member to select a machine in a process. However, the selection member is not limited to tabs. For example, selection may be made from a pull-down menu.

By displaying the history of abnormalities in a table format, workers can easily recognize the occurrence of abnormalities. By displaying the operation status and signals of each machine in each process in a chart format, it is possible to identify abnormalities and easily narrow down candidate causes.

Additionally, the operator can run the production line in the usual way, specify the period during which the monitoring system detects the signals used by the machines, and specify the period during which the judgment threshold is determined, thereby reducing the number of machines or signals. Even if the number increases, a monitoring system can be easily established.

The disclosed technology can be used in a production line production system used in factories, etc.

Other Embodiments

Embodiments of the present invention include computer execution recorded on a storage medium (which may be referred to in more detail as a 'non-transitory computer-readable storage medium') to perform one or more functions of the above-described embodiment(s) of the present invention. One or more circuits (e.g., application specific integrated circuit (ASIC)) that read and execute possible instructions (e.g., one or more programs) and/or perform one or more functions of the above-described embodiment(s) by a computer of the system or device comprising a The computer may have one or more central processing units (CPUs), microprocessing units (MPUs), or other circuits, and may have a network of separate computers or separate computer processors. Computer-executable instructions may be given to the computer, for example, from a network of storage media.Recording media can be, for example, one or more hard disks, random access memory (RAM), read-only memory (ROM), Storage of a distributed computing system, optical disk (compact disk (CD), digital versatile disk (DVD), or Blu-ray disk (BD) ^TM , etc.), flash memory device, memory card, etc. may be provided.

The present invention provides a program that realizes one or more functions of the above-described embodiments to a system or device via a network or storage medium, and one or more processors in the computer of the system or device read and execute the program. It is also executable in processing. Additionally, it can also be executed by a circuit (eg, ASIC) that realizes one or more functions.

Although the invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to these embodiments. The scope of protection of the following claims should be interpreted in the broadest manner to encompass all modifications, equivalent structures and functions.

Claims (42)

delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete A control device, in a production line including a plurality of sensors and a plurality of devices, configured to acquire information about the device, and configured to have the sensor output a sensor signal in accordance with operation of the device,
a control unit configured to operate a first device and a second device among the plurality of devices based on a control signal;
A monitoring unit configured to acquire the sensor signal, the control signal, and operation information, which is information regarding operation of the first device and the second device,
The control unit, based on the control signal, causes the first device to operate in a first cycle and causes the first device and the second device to operate in a second cycle following the first cycle,
wherein the monitor identifies first sensor signals and first control signals associated with the first device that have changed while the first device is operating in a first cycle;
The monitoring unit includes a second sensor signal and a second control signal related to the second device, wherein the first sensor signal and the first control signal are changed while the second device is operating in a second cycle. 1 A control device that identifies the sensor signal and the control signal other than the control signal.
According to claim 17,
Further provided with a display unit,
A first timing, which is the timing at which the first sensor signal, the first control signal, the second sensor signal, or the second control signal is changed, is compared with a threshold, and based on the difference between the first timing and the threshold, A control device that displays abnormality information indicating the occurrence of an abnormality on the display unit.
According to claim 18,
The range of the threshold is displayed on the display unit together with the first sensor signal, the first control signal, the second sensor signal, or the second control signal.
According to claim 17,
Further provided with a display unit,
The operation information is displayed in the form of a first bar chart on the display unit,
The first sensor signal or the second sensor signal is displayed in the form of a second bar chart on the display unit,
The first control signal or the second control signal is displayed in the form of a third bar chart on the display unit.
According to claim 20,
The second bar chart indicates that the first sensor signal or the second sensor signal is in an ON state.
According to claim 20,
The threshold regarding the first timing, which is the timing at which the first sensor signal, the second sensor signal, the first control signal, or the second control signal is changed, is determined by the display form of the second bar chart and the third A control device displayed on the display unit in a display format different from that of a bar chart.
According to claim 22,
The control device wherein the threshold value is displayed on the display unit as a broken line overlapping a part of the second bar chart or a part of the third bar chart.
According to claim 19,
The abnormality information may be a display form of the first sensor signal, the second sensor signal, the first control signal, or the second control signal where the first timing is outside the range, and the first timing is within the range. A control device displayed on the display unit in a display format different from the first sensor signal, the second sensor signal, the first control signal, or the second control signal.
According to claim 17,
Further provided with a display unit,
The name of the first device or the second device, the name of the operation performed by the first device or the second device, the name of the command causing the first device or the second device to operate, or the first control At least one of the signal symbols representing the signal or the second control signal is displayed on the display unit as information about the first sensor signal, the second sensor signal, the first control signal, or the second control signal. Control device.
According to claim 18,
The control device further includes a storage unit that stores the first timing and a second timing at which the first device or the second device starts operation.
According to claim 26,
A control device wherein the threshold value is determined from a value stored in the storage unit.
According to claim 17,
Further provided with a display unit,
Upon selection of the first device or the second device on the display, the first sensor signal, the second sensor signal, the first control signal or the second control associated with the first device or the second device. Control device where signals are displayed.
According to claim 17,
The sensor is a control device that changes from an OFF state to an ON state, or from an ON state to an OFF state, with respect to the sensor signal and the control signal.
delete According to claim 17,
The control device wherein the first device or the second device, the first sensor signal, the second sensor signal, the first control signal or the second control signal are automatically related to each other by the monitoring unit.
According to claim 17,
The monitoring unit sequentially records the first sensor signal and the first control signal in a list in the first cycle, and records other than the first sensor signal and the first control signal based on the list in the second cycle. A control device that identifies the sensor signal and the control signal.
According to claim 17,
A control device wherein the plurality of devices include at least one of an input unit, an adhesive application unit, and an discharge unit.
A method of manufacturing an article in which the article is manufactured using a production line in which information is acquired by the control device according to claim 17,
The plurality of devices in the production line include a conveyor, an input unit, and an adhesive application unit,
The control unit inputs the work into the conveyor using the input unit,
A method of manufacturing an article, wherein the control unit manufactures the article by applying an adhesive to the work using the conveyor and the adhesive application unit.
A control method used by a control device configured to acquire information about the device in a production line including a plurality of sensors and a plurality of devices, wherein the sensor is configured to output a sensor signal in accordance with operation of the device, comprising:
operating, by a control unit of the control device, a first device and a second device among the plurality of devices based on a control signal;
A step of acquiring, by a monitoring unit of the control device, the sensor signal, the control signal, and operation information, which is information about the operation of the first device and the second device,
By the control unit of the control device, based on the control signal, the first device is operated in a first cycle, and the first device and the second device are operated in a second cycle following the first cycle. do,
wherein the monitor identifies first sensor signals and first control signals associated with the first device that have changed while the first device is operating in a first cycle;
The monitoring unit includes a second sensor signal and a second control signal related to the second device, wherein the first sensor signal and the first control signal are changed while the second device is operating in a second cycle. 1 A control method for identifying the sensor signal and the control signal other than the control signal.
A non-transitory computer-readable storage medium storing a program capable of executing the control method according to claim 35.
According to claim 18,
A control device wherein the monitoring unit acquires a first timing in a plurality of cycles and acquires a threshold value based on a statistical quantity of the first timing.
According to claim 17,
The monitoring unit controls to identify the first sensor signal, the second sensor signal, the first control signal, and the second control signal based on a gradual increase in the number of devices that start operation so that the plurality of devices are operated. Device.
According to claim 17,
The control device wherein the monitoring unit identifies the first sensor signal, the second sensor signal, the first control signal, and the second control signal based on a gradual decrease in the number of operating devices in the plurality of devices in operation.
According to claim 17,
A control device wherein the monitoring unit identifies the first sensor signal, the second sensor signal, the first control signal, and the second control signal based on a period specified by the user.
According to claim 17,
The monitoring unit operates based on the period from the timing when the first device or the second device transitioned from the standby state to the operating state to the timing when the first device or the second device transitioned from the operating state to the standby state. A control device that acquires information. According to claim 17,
The control unit operates only the first device in the first cycle, and operates the first device and the second device in the second cycle.

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